Singulating system for high capacity baler

ABSTRACT

A square baler comprising a first bale-forming area in which are formed a first series of first individual bales, and a second bale-forming area in which are formed a second series of second individual bales. The square baler additionally comprises a singulator configured to receive the first and second individual bales from the first and second bale-forming areas and to form a single row of the first and second individual bales.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present non-provisional patent application claims priority to U.S. Provisional Patent Application Ser. No. 62/801,982, filed on Feb. 6, 2019, and entitled “HIGH CAPACITY SQUARE BALER,” and to U.S. Provisional Patent Application Ser. No. 62/790,249, filed on Jan. 9, 2019, and entitled “HIGH CAPACITY SQUARE BALER,” with the entireties of both above-identified, previously-filed provisional applications being hereby incorporated by reference into the present non-provisional patent application.

FIELD OF THE INVENTION

Embodiments of the present invention are generally directed to high capacity balers. More particularly, embodiments of the present invention are directed to balers with singulators for manipulating a plurality of bales into a single row of bales.

BACKGROUND OF THE INVENTION

Balers are agricultural implements that form bales (e.g., square or round-shaped bales) of crop material. Most currently available square balers use a single baling chamber with a single gearbox, a single plunger, and a single knotter assembly to produce one square bale at a time. To increase baling efficiency, there is a desire to increase the capacity of some balers to produce more bales per hour. One way to increase baler capacity is to run the baler's plunger faster; however, due to concerns with knotter assembly reliability at high speeds, plunger speeds have maxed out at approximately one hundred revolutions per minute. Another option to increase baler capacity is to use thicker flakes when forming the bales; however, end users of bales often object to bale flakes being too large. Also, larger flakes can lead to inconsistent bale lengths.

These limitations have led to special hitches that pull two balers with one tow vehicle. While this solution can increase bale production, the use of two balers negatively impacts maneuverability of the tow vehicle and/or of the balers during both field operation and transport.

SUMMARY OF THE INVENTION

In one embodiment of the present invention, there is provided a square baler comprising a first bale-forming area within which are formed a first series of first individual bales, and a second bale-forming area within which are formed a second series of second individual bales. The square baler additionally comprises a singulator configured to receive the first and second individual bales from the first and second bale-forming areas and to form a single row of the first and second individual bales.

In another embodiment of the present invention, there is provided a method of sorting a plurality of bales of crop material. The method comprises a step of forming bales of crop material within a first bale-forming area and within a second bale-forming area. An additional step includes dispensing a first series of first individual bales from the first bale-forming area. An additional step includes dispensing a second series of second individual bales from the second bale-forming area. A further step includes positioning the first and second individual bales dispensed respectively from the first and second bale forming chambers into a single row of bales.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

BRIEF DESCRIPTION OF THE FIGURES

Embodiments of the present invention are described herein with reference to the following drawing figures, wherein:

FIG. 1 is a front, left-side perspective view of a baler according to embodiments of the present invention;

FIG. 2 is a rear, right-side perspective view of the baler from FIG. 1;

FIG. 3 is a top plan view of the baler from FIGS. 1 and 2, with a portion in front of the baler, including a chassis, removed;

FIG. 4 is a cross-section of the baler from FIGS.1-3, taken along the line 4-4 from FIG. 3, and provided with arrows to illustrate crop material flow through the baler;

FIG. 5 is a front perspective view of the baler from FIGS. 1-4, provided with arrows to illustrate crop material flow through the baler, and with a portion of the baler removed to illustrate stuffer chutes, stuffer assemblies, and baling chambers of the baler;

FIG. 6 is a front perspective view of a rotor housing and a pickup assembly from the baler from FIGS. 1-5, with a rotor being positioned within the rotor housing;

FIG. 7 is a front, left-side perspective view of the baler of FIGS. 1-6, with portions of the baler removed and shown in dashed line, so as to illustrate crop material flowing from a left-side stuffer chute into a left-side baling chamber;

FIG. 8 is a front, right-side perspective view of the baler of FIGS. 1-6, with portions of the baler removed and shown in dashed line, so as to illustrate crop material flowing from a right-side stuffer chute into a right-side baling chamber;

FIG. 9 is a front, left-side view of a gearbox and plungers positioned with the baling chambers of the baler from FIGS. 1-8, with portions of the baler removed or shown in dashed line for clarity;

FIG. 10 is a front, right-side view of the gearbox and plungers positioned with the baling chambers of the baler from FIG. 9;

FIG. 11 is a front left-side view of knotter assemblies and stuffer assemblies from the baler of FIGS. 1-8 being rotationally linked via chains and sprockets;

FIG. 12 is a left-side elevation view of a portion of the baler from FIGS. 1-8, particularly showing a bale of crop material being formed in a left-side baling chamber and a needle of a knotter assembly in a lowered position;

FIG. 13 is a left-side elevation view of the portion of the baler from FIG. 12, particularly showing the needle in a raised position;

FIG. 14 is a rear perspective view of a portion of a baler comprising a singulator according to embodiments of the present invention, with the singulator attached rearward of baling chambers of the baler;

FIG. 15 is a bottom perspective view a portion of the baler and of the singulator from FIG. 14;

FIG. 16 is a side elevation view of a portion of the baler and of the singulator FIGS. 14 and 15;

FIG. 17 is another rear perspective view of the singulator from FIGS. 14-16;

FIG. 18 a top plan view a portion of the baler and of the singulator from FIGS. 14-16, particularly illustrating how a first individual bale and a second individual bale flow though the singulator from the baling chambers into a single row of bales;

FIG. 19 is a rear perspective view of a portion of a baler comprising a singulator according to other embodiments of the present invention, with the singulator attached rearward of baling chambers of the baler;

FIG. 20 is a bottom perspective view a portion of the baler and of the singulator from FIG. 19;

FIG. 21 is a side elevation view of a portion of the baler and of the singulator FIGS. 19 and 20, with a portion of a chassis extension cut away to illustrate a conveyor;

FIG. 22 is another rear, right side perspective view of a portion of the baler and of the singulator from FIGS. 19-21;

FIG. 23 is a rear, right side perspective view of the portion of the baler and of the singulator from FIG. 22, particularly illustrating a left side dump cradle in a bale dumping position;

FIG. 24 is a rear, right side perspective view of the portion of the baler and of the singulator from FIG. 22, particularly illustrating a right side dump cradle in a bale dumping position;

FIG. 25 is another rear perspective view of a portion of the baler and of the singulator from FIGS. 19-21, particularly illustrating a landing section which includes left side and right side dump cradles, and further illustrating portions of an exit section positioned below the landing section;

FIG. 26 is a top plan view of a portion of the baler and of the singulator from FIGS. 19-21;

FIG. 27 is a perspective view of the singulator taken along the line 27-27 from FIG. 26;

FIG. 28 is another rear perspective view of a portion of the baler and of the singulator from FIGS. 19-21, particularly illustrating left and right dump cradles in a bale receiving position and with a bale of crop material being supported by the right side dump cradle;

FIG. 29 is a rear perspective view of the portion of the baler and of the singulator from FIG. 28, particularly illustrating the right dump cradle in a bale dumping position such that a bale of crop material is dropped down onto a receiving tray of an exit section of the singulator;

FIG. 30 is another perspective cross section view of the singulator from FIG. 27, particularly illustrating a bale supported on a receiving tray of an exit section of the singulator;

FIG. 31 is a perspective cross section view of the singulator from FIG. 30, particularly illustrating a conveyor pushing the bale rearward along the receiving tray;

FIG. 32 is a top plan view of a portion of the baler and of the singulator from FIGS. 19-21, particularly illustrating a bale flowing from the baling chambers and through the singulator to form a single row of bales;

FIG. 33 is a rear perspective view of a portion of a baler comprising a singulator according to yet other embodiments of the present invention, with the singulator attached rearward of baling chambers of the baler;

FIG. 34 is another rear perspective view of a portion of a baler and the singulator from FIG. 33, particularly illustrating a left side lift cradle in a bale ejecting position; and

FIG. 35 is another rear perspective view of a portion of a baler and the singulator from FIG. 33, particularly illustrating a right side lift cradle in a bale ejecting position.

The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

DETAILED DESCRIPTION

The following detailed description of the present invention references various embodiments. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

Broadly, embodiments of the present invention are directed to agricultural implements in the form of crop balers, such as baler 10 illustrated in FIGS. 1 and 2, which are configured to simultaneously form two or more bales of crop material from a single windrow of the crop material. In some embodiments, the baler 10 will be configured to form square bales of crop material, such that the baler 10 is a square baler.

The baler 10 may include a wheeled chassis 12 including an axle 14 and a pair of laterally spaced wheels 16 that support the chassis 12 above the ground. The baler 10 may additionally comprise a plurality of baling chambers 18, extending generally in a fore-and-aft direction and which are supported on top of the chassis 12. As will be described in more detail below, the baling chambers 18 are configured as bale forming chambers in which small, square bales of crop material can be formed. Because the baler 10 includes a plurality of baling chambers 18, the baler 10 may be referred to as a “high capacity” baler capable of simultaneously forming multiple bales of crop material. In some specific embodiments, the baler 10 will include two baling chambers 18 supported on the chassis 12 and positioned between the wheels 16. As will be described in more detail below, the plurality of baling chambers 18 permits the baler 10 to simultaneously form a plurality of bales of crop material. In some embodiments, the plurality of bales of crop material may be formed by the baler 10 picking up crop material from a single windrow of crop material.

In some embodiments, the baler 10 may be pulled or pushed by a towing vehicle (e.g., a tractor, which is not shown in the drawings). In alternative embodiments, the baler 10 may be self-propelled. For example, the baler 10 may include an internal combustion engine and any other components necessary for the baler 10 to operate independently of any other machine or towing vehicle. Returning to embodiments in which the baler 10 is pulled by a towing vehicle, the chassis 12 of the baler 10 may include a forwardly-extending tongue 20, as illustrated in FIGS. 1 and 2, for connecting the baler 10 to the towing vehicle. A forward end of the tongue 20 may include a hitch for facilitating the connection with the towing vehicle, while a rearward end of the tongue 20 may be pivotally connected to the chassis 12. It will be appreciated that, as used herein, the terms “front” or “forward” refers to a direction towards a free end of the tongue 20 of the baler 10, while the terms “back,” “rear,” or “rearward” refer to an opposite direction (i.e., away from the free end of the tongue 20 of the baler 10). Correspondingly, the terms “left,” “left-side,” “right,” and “right-side” should generally be interpreted as corresponding to the appropriate directions when viewing the front of the baler 10 while positioned at the back of the baler 10. As such, for example, the left-side of the baler 10 is shown in the foreground of FIG. 1, while the right-side of the baler is shown in the foreground of FIG. 2. The tongue 20 is generally configured to connect the baler 10 with the towing vehicle in a manner that allows the baler 10 to be positioned directly behind the towing vehicle. As such, the baler 10 can pick up crop material from a single windrow that is passed over first by the towing vehicle and then by the baler 10. As such, the baler 10 may, in some embodiments, be configured as an “in-line” baler, as will be discussed in more detail below.

To collect crop material laying on the ground in a windrow, the baler 10 may include a pickup mechanism 22, as perhaps best illustrated in FIGS. 1, 3, and 4, which is supported on the chassis 12 below the baling chambers 18. In some embodiments, the pickup mechanism 22 may extend down from the chassis 12 and may be positioned in front of the wheels 16. As such, the pickup mechanism 22 may be centered about a longitudinal centerline of the baler 10, so as to permit the pickup mechanism 22 to pick up crop material within a single windrow as the baler 10 is advanced along a path of travel by the towing vehicle (i.e., with the path of travel extending over the path presented by the windrow). To facilitate the collection of the crop material, the pickup mechanism 22 may comprise a tined, rotating member, which is configured to pick up the crop material of the windrow off the ground. Upon picking up the crop material, the pickup mechanism 22 will be further configured to transfer the crop material upward and rearward to a rotor housing 24 illustrated in FIGS. 1-5.

The rotor housing 24 may also be positioned below the baling chamber 18 and is generally configured to rotatably support a rotor 26 within the rotor housing 24. The rotor 26 is shown in more detail in FIG. 6. The rotor 26 may be configured to convey the crop material from the rotor housing 24, as illustrated in FIG. 4, rearward to one or more stuffer chutes 28. The stuffer cutes 28 are perhaps best illustrated in FIGS. 4, 7, and 8. In some embodiments, the baler 10 may include the same number of stuffer chutes 28 as baling chambers 18, such that crop material may be passed from each stuffer chute 28 into a specific baling chamber 18. For example, the embodiment of the baler 10 illustrated in the figures includes two baling chambers 18. As such, the baler 10 of the figures may correspondingly include two stuffer chutes 28, with each stuffer chute 28 being associated with one baling chamber 18 so as to provide crop material to the associated baling chamber 18.

Returning to the rotor housing 24 and the rotor 26, the rotor housing 24 and/or the rotor 26 may be particularly configured to direct crop material received from the pickup mechanism 22 generally evenly into each stuffer chute 28 of the baler 10. For example, as illustrated by FIG. 6, the rotor 26 may be formed as an auger with one or more auger flightings and/or toothed sections configured to direct crop material generally evenly into each stuffer chute 28. In more detail, the rotor 26 may comprise a spindle 30 from which is extended a first toothed section 32, a second toothed section 34, and an interior auger-flighted section 36 located between the first and second toothed sections 32, 34. The first and second toothed sections 32, 34 may each include a plurality of tooth elements extending outward from the spindle 30. The interior auger-flighted section 36 may include one or more sets of helically-shaped auger flightings. In some embodiments, the interior auger-flighted section 36 may include a first set of interior flights 38 configured to push crop material in a first direction and a second set of interior flights 39 configured to push crop material in a second direction generally opposite from the first direction. For example, the first set of interior flights 38 may be configured to push crop material outwardly toward the first toothed section 32, and the second set of interior flights 39 may be configured to push crop material outwardly toward the second toothed section 34.

In some embodiments, the rotor 26 may further comprise a first exterior auger-flighted section 40 and a second exterior auger-flighted section 42 positioned on either end of the spindle 30. As such, the first toothed section 32 may be situated between the first exterior auger-flighted section 40 and the interior auger-flighted section 36 (e.g., the first set of interior flights 38). Similarly, the second toothed section 34 may be situated between the second exterior auger-flighted section 42 and the interior auger-flighted section 36 (e.g., the second set of interior flights 39). As such, the first exterior auger-flighted section 40 is configured to push crop material inwardly toward the first toothed section 32, whereas the second exterior auger-flighted section 42 is configured to push crop material inwardly toward the second toothed section 34. State differently the first exterior auger flighted section 40 is configured to push crop in a first direction and the second set of interior flighted section 42 is configured to push crop in a second direction generally opposite the first direction.

To further facilitate the distributions and processing of crop material, some embodiments of the baler 10 may include a stationary separation element 44 extending upward from a bottom panel of the rotor housing 24. In some embodiments, the separation element 44 may have a sharpened forward edge so as to act as a blade-like dividing member for cutting crop material that is forced into contact with the separation element 44. In some embodiments, the rotor 26 may include a gap between the first and second sets of interior flights 38, 39 of the interior auger-flighted section 36, such that the separation element 44 can be at least partly received in the gap as the rotor 26 rotates. In some further embodiments, the rotor 26 may further comprise a first interior tooth 46 and second interior tooth 48, which are both positioned between the first and second sets of interior flights 38, 39 of the interior auger-flighted section 36. In some embodiments, the first and second interior teeth 46, 48 may be spaced apart from each other so as to present the gap between the first and second sets of interior flights 38, 39 of the interior auger-flighted section 36. As such, the first set of interior flights 38 may terminate at the first interior tooth 46, while the second set of interior flights 39 may terminate at said second interior tooth 48. Thus, in such embodiments, the first and second interior teeth 46, 48 may be configured to pass on either side of the separation element 44 when the rotor 26 is rotating.

Given the above-described rotor 26 and the separation element 44, embodiments provide for crop material provided to the rotor housing 24 by the pickup mechanism 22 to be directed generally evenly to each of the stuffer chutes 28. In more detail, the baler 10 may, as illustrated in the FIGS. 7 and 8, include two stuffer chutes 28 and two baling chambers 18, with each stuffer chute 28 being associated with one of the baling chambers 18. For example, as shown in FIG. 7, left-side the stuffer chutes 28 may be associated with a left-side baling chamber 18. As shown in FIG. 8, right-side stuffer chutes 28 may be associated with a right-side baling chamber 18. Each of the stuffer chutes 28 may comprise a lower entrance and an upper exit. As such, and as perhaps best illustrated in FIG. 4, crop material is provided from the pickup mechanism 22 into the stuffer chutes 28 via the lower entrances of the stuffer chutes 28, while crop material exits from the stuffer chutes 28 (e.g., into the baling chambers 18) via the upper exits of the stuffer chutes 28. In some embodiments, the lower entrance of each stuffer chute 28 will be wider (or will generally have a larger internal cross section) than the upper exit. As such, crop material introduced into the stuffer chutes 28 can be pre-compressed during travel from the lower entrance to the upper exit in preparation for introduction into the baling chambers 18. In some embodiments, a ratio of a width (or internal cross section size) of the lower entrance of the stuffer chutes 28 to a width (or internal cross section size) of the upper exit of the stuffer chutes is at least 1.1:1, at least 1.25:1, or at least 1.5:1, and/or not more than 2.5:1, not more than 2:1, or not more than 1.75:1.

To evenly distribute the crop material to the stuffer chutes 28, the first toothed section 32 of the rotor 26 may be aligned with the left-side stuffer chute 28, and the second toothed section 34 of the rotor 26 may be aligned with the right-side stuffer chute 28. As such, when the rotor 26 is rotated (e.g., generally in a counter-clockwise direction when viewing from the left side of the baler 10, as in FIG. 4), the first and second toothed sections 32, 34 can force crop material received from the pickup mechanism 22 downward below the rotor 26 and rearward into the respective stuffer chutes 28. As perhaps best illustrated in FIG. 5, crop material that is received into the rotor housing 24 from the pickup mechanism 22 at a location adjacent to a center of the rotor 26 may be forced outwardly by the interior auger-flighted section 36 towards either the first or second toothed section 32, 34. In some embodiments, portions of the crop material will come into contact with the stationary separation element 44 extending upward from the bottom panel of the rotor housing 24. As noted previously, the separation element 44 may extend upward from generally a center of the bottom panel of the rotary housing 24, such that the separation element 44 extends upward into the gap presented by the first and second interior teeth 46, 48. Thus, crop material may be cut by the separation element 44, as the crop material is forced into the stationary element by the rotating first and second interior teeth 46, 48. The separation element 44 may be positioned generally between the lower entrances of the stuffer chutes 28. As such, crop material cut by the separation element 44 can be forced outward by the interior auger-flighted section 36 towards either the first or second toothed section 32, 34, so as to be provided to the respective stuffer chutes 28. Furthermore, crop material that is received into the rotor housing 24 from the pickup mechanism 22 at locations adjacent to ends of the rotor 26 may be forced inwards by the first and second exterior auger-flighted section 40, 42 respectively toward either the first or second toothed section 32, 34, so as to be provided to the respective stuffer chutes 28.

Thus, the baler 10 is particularly configured to collect crop material from a single windrow and process such crop material into a plurality of crop streams. For example, in embodiments that include two baling chambers 18, the crop material may be provided in a first crop stream to a first of the stuffer chutes 28 (e.g., the left-side stuffer chute 28), and in a second crop stream to a second of the stuffer cutes 28 (e.g., the left-side stuffer chute 28). As will be described in more detail below, crop material from the first crop stream may be transferred through the left-side stuffer chute 28 to the left-side baling chamber 18 for formation of bales of crop material. Similarly, crop material from the second crop stream may be transferred through the right-side stuffer chute 28 to the right-side baling chamber 18 for formation of bales of crop material.

In some embodiments, each of the stuffer chutes 28 may be associated with stuffer assembly 50, as shown in FIGS. 7 and 8, for forcing crop material to flow rearward and/or upward through the stuffer chute 28 from the lower entrance to the upper exit. Each stuffer assembly 50 may include a base element 50(a) and plurality of stuffer forks 50(b) extending from the base element 50(a). The stuffer forks 50(b) are configured to extend through slots formed in forward panels of the stuffer chutes 28, such that the stuffer forks 50(b) can be caused to pass along a length of the stuffer chute 28 (from the lower entrance to the upper exit) so as to force crop material from the lower entrance to the upper exit. As will be described in more detail below, actuation of the stuffer fork 50(b) of the stuffer assemblies 50 through the stuffer chutes 28 may be caused by rotation of the base elements 50(a) of the stuffer assemblies 50. As was described previously, the width and/or the internal cross section of the upper exit of each stuffer chute 28 is generally smaller than that of the lower entrance. As such, the crop material passing from the lower entrance to the upper exit of a stuffer chute 28 will experience a compressive force (i.e., a pre-compression on the crop material exerted by sides of the stuffer chute 28) before the crop material is provided to its associated baling chamber 18. As illustrated in FIGS. 4, 7, and 8, the upper exit of each stuffer chute 28 is in communication with a forward end of its associated baling chamber 18 (at a bottom side of the baling chamber 18), so that pre-compressed crop material can be provided into the baling chamber 18. Each rotation of the stuffer assembly 50 may force a “charge” of crop material into its associated baling chamber 18.

Upon introduction of a charge of crop material into one of the baling chambers 18, the baler 10 is configured to further compress the crop material into a square bale of crop material. As illustrated in FIGS. 1, 2, 4, 7, and 8, each baling chamber 18 may generally comprise an elongated chamber with a crop inlet at a forward end for receiving charges of crop material from the associated stuffer chute 28 and a bale discharge at a rearward end from which square bales of crop material are discharged from the baling chamber 18 and the baler 10. The crop inlet of each baling chamber 18 may be positioned at the bottom of the baling chamber 18, as illustrated in FIGS. 4, 7, and 8, such that baling chambers are considered “bottom fed,” with charges of crop material being provided into the baling chambers from below the baling chambers 18 via associated stuffer chutes 28.

As illustrated in FIGS. 9 and 10, each baling chamber 18 may be associated with a plunger 52 configured to compressing the crop material within the baling chamber 18 to form the square bale of crop material. The plungers 52 may each comprise a generally rectangular head having a size at least nominally smaller than a bailing chamber 18, such that the plunger can reciprocate within the baling chamber 18 to compact crop material into a bale. In more detail, in the embodiments shown in the figures, the baler 10 may include two plungers 52, with each plunger 52 being associated with one of the baling chambers 18. Each plunger 52 may be reciprocated within its respective baling chamber 18 between a retracted position and an extended position. In the retracted position (e.g., the solid line plunger 52 of FIG. 4), the plunger 52 may be positioned forward of the baling chamber's 18 crop inlet, such that a charge of crop material may be introduced into the baling chamber 18 from the associated stuffer chute 28. Upon introduction of the charge of crop material into the baling chamber 18, the plunger 52 may be actuated rearward in a compaction stroke (e.g., the dashed line plunger 52 of FIG. 4) so as to compress the charge of crop material into a flake of a square bale. The plunger 52 will continue reciprocating between retracted and extended positions, as charges of crop material are added into the baling chamber 18, so as to compress crop material into a fully formed square bale. By having multiple baling chambers 18, each being associated within its own plunger 52, the baler 10 is configured to simultaneously create multiple bales of crop material, with such crop material being obtained by the baler 10 from a single windrow.

In more detail, and with reference to FIG. 2, each baling chamber 18 may be generally rectangular with a pair of sidewalls 54, a top wall 56, and a bottom wall 58. In some embodiments, the walls 54, 56, 58 may each be formed from one or more rails that are configured and/or secured together in a rectangular shape. As such, the walls 54, 56, 58 of each baling chamber 18 define an interior baling space within which the plunger 52 can extend and retract so as to compress crop material into square bales. The interior baling space is generally of a fixed dimension, such that each new charge of crop material received from the associated stuffer chute 28 can be packed and compressed rearwardly as a flake of crop material against previously compacted flakes that will collectively form a bale of crop material.

In some embodiments, a cross-sectional area of each baling chamber 18 may decrease moving from a forward end to a rearward end of the baling chamber 18. Such a reduction in a cross-sectional area can facilitate the ability of the baling chambers 18 to compress the crop material into square bales during formation of the bales. As such, the baling chambers 18 may be configured to exert pressure on all four sides of the bales as the bales move rearward through the baling chambers 18. Furthermore, in some embodiments, each baling chamber 18 may include an independent compression assembly 60, as shown in FIG. 2, for aiding in compression of the walls 54, 56, 58 of the baling chambers 18. In some embodiments, the compression assemblies 60 may be positioned near the rearward ends of the baling chambers 18. Each compression assembly 60 may include a vertical compression mechanism for adjusting a vertical distance between the top wall 56 and the bottom wall 58, as well as a horizontal compression mechanism for adjusting the horizontal distance between the sidewalls 54. In some embodiments, each of the vertical and horizontal compression mechanisms may comprise hydraulic, pneumatic, or electrical cylinders, configured to be manually or automatedly adjustable. As such, each baling chamber 18 may be configured, e.g., due to the compression provided by the compression assembly 60, to exert pressure on all four sides of the bales formed therein. In addition to facilitating compression, in some embodiments, the compression assemblies 60 may also be used to adjust the size of the discharge openings presented by the rearward ends of the baling chambers 18. The use of independent compression assemblies 60 with each baling chamber 18, allows for the baler 10 to establish a set pressure on each side of a bale being formed in a given baling chamber 18 so as to minimize variation in bale length and density.

As noted above, the baler 10 according to embodiments of the present invention may include a plurality of baling chambers 18, each being configured to generate individual square bales of crop material. As such, the baler 10 can simultaneously form multiple square bales from crop material obtained from a single windrow. In some embodiments, as illustrated in the figures, the baler 10 will include two spaced apart, side-by-side baling chambers 18. Such baling chambers 18 may extend in a generally fore-and-aft direction with respect to the chassis 12. The baling chambers 18 may extend in a generally parallel relationship with each other (and/or with the longitudinal centerline of the of the chassis 12 and/or the baler 10), with one baling chamber 18 positioned on one side of the longitudinal centerline of the chassis 12 of the baler 10, and the other baling chamber 18 positioned on the other side of the longitudinal centerline of the chassis 12 of the baler 10. In some embodiments, the baling chambers 18 may be spaced from one another by not more than sixty inches, not more than forty-eight inches, not more than thirty-six inches, or not more than twenty-four inches. In alternative or additional embodiments, the baling chambers 18 may be spaced from one another by at least one inch, at least three inches, at least six inches, at least twelve inches, or at least eighteen inches. Beneficially, having the baling chambers 18 spaced apart can make it simpler to implement mechanisms that handle, accumulate, and/or sort bales that are formed in and dispensed from the baling chambers 18.

In alternative embodiments, the baling chambers 18 may not be spaced apart from each other. For example, the baling chambers 18 may be separated by (or share) a common interior wall, such that no air gap exists between the baling chambers 18. For example, the common interior wall may comprise the interior sidewall 54 of the adjacent baling chambers 18, such that the baling chambers 18 are not spaced apart. In some embodiments, an entire length of the baling chambers 18 may be separated by the common interior wall.

In some further embodiments, the baling chambers 18 may not be separated by any interior walls. For example, four walls (e.g., a pair of sidewalls 54, a top wall 56, and a bottom wall 58) may define a common interior baling space that includes two baling chambers 18. As such, the two baling chambers 18 can share a common interior baling space so that two bales can be simultaneously formed within the common interior baling space.

As was noted above, each of the baling chambers 18 may include a plunger 52 for compacting crop material in the baling chamber 18 to form a square bale of crop material. In an embodiment of the baler 10 that include two baling chambers 18, as shown in the figures, the baler 10 may include two plungers 52 (See, e.g., FIGS. 9 and 10). In such embodiments, the plungers 52 may be driven, directly or indirectly, by a common gearbox 70, which is illustrated in FIGS. 1-4, 9, and 10. The gearbox 70 may be supported on top of the chassis 12 and positioned adjacent to the front of the chassis 12. As such, a rotating power source, such as power take-off 72 from the tow vehicle (See, e.g., FIGS. 1 and 2), may be engaged with the gearbox 70 to provide rotary power from the tow vehicle to the baler 10. As illustrated in FIG. 1, the gearbox 70 may comprise an input element 73, which is configured to be rotated by the rotating power source, e.g., the power take-off 72, about an input axis of rotation so as to provide rotational power to the gearbox 70. The baler 10 may additionally include a flywheel 74 positioned between the gearbox 70 and the power take-off 72, which is configured to store rotational energy for provision to the gearbox 70 as necessary. In some alternative embodiments, the baler 10 may include a rotating power source in the form of a hydraulic pump/motor (not shown). The hydraulic pump/motor may, in some embodiments, itself be engaged with the power take-off 72 to receive power from the tow vehicle. Regardless, the gearbox 70 may be connected with the pump gearbox to receive rotary power therefrom.

In some embodiments, as shown in FIGS. 3, 9, and 10, the gearbox 70 may comprise a first drive shaft section 76 extending outward from a first side (e.g., a left side) of the gearbox 70, and a second drive shaft section 78 outward from a second side (e.g., a right side) of the gearbox 70. As such, the first and second drive shaft sections 76, 78 may extend outwardly from generally opposite sides of the gearbox 70. The first and second drive shaft sections 76, 78 may be configured to rotate on respective first and second drive shaft axes of rotation. In certain embodiments, each of the first and second drive shaft axes of rotation is angled relative to the input axis of rotation of the gearbox 70 (as presented by the input element 73) between sixty and one-hundred twenty degrees, between seventy and one-hundred degrees, or between eighty and one hundred degrees. In some embodiments, the first and second drive shaft axes of rotation may be skewed. In other embodiments, the first and second drive shaft axes of rotation may be parallel or colinear. For example, the first and second drive shaft sections 76, 78 may be configured to rotate on a common substantially horizontal axis of rotation. The gearbox 70 may further include a common drive shaft extending through the gearbox 70 and comprising the first and second drive shaft sections 76, 78.

In general, the gearbox 70 is configured as a rotating power source that is used to rotate the first and second drive shaft sections 76, 78 using power from the external rotating power source, e.g., the power take-off 72. In some embodiments, the gearbox will be configured to rotate the first and second drive shaft sections 76, 78 at generally equal speeds (i.e., at equivalent rates of rotation). In embodiments of the baler 10 that include two plungers 52, as illustrated in FIGS. 3, 9, and 10, a left-side plunger 52 may be coupled to the first drive shaft section 76, while a right-side plunger 52 may be coupled to the second drive shaft section 78. As such, the left-side plunger 52 may be positioned on an opposite side of the gearbox 70 as the right-side plunger 52. As illustrated in FIGS. 9 and 10, each of the drive shaft sections 76, 78 may be connected to a respective plunger 52 via a connecting element 80 that is pivotally connected between the plunger 52 and respective ones of the drive shaft sections 76, 78 so as to transfer the generally circular movement of the drive shaft sections 76, 78 to reciprocation actuations of the plungers 52. To further facilitate such reciprocating actuation, each plunger 52 may include an elongated connection arm, with a first end pivotally connected to the head of the plunger 52 and a second end pivotally connected to the connecting element 80.

Under power from the gearbox 70, rotation of the first drive shaft section 76 will cause reciprocation of the left-side plunger 52 and rotation of the second drive shaft section 78 will cause reciprocation of the right-side plunger 52. As was described previously, each of the plungers 52 is configured to reciprocate between the extended position and the retracted position. The gearbox 70 may, in some embodiments, be configured to actuate the plungers 52, such that the left-side and right-side plungers 52 are reciprocated in an alternative fashion. As such, when the left-side plunger 52 is in the extended position, the right-side plunger 52 is in the retracted position, and vice versa. Such positioning may be facilitated by the connecting elements 80 being orientated generally one-hundred eighty degrees out of phase (in certain embodiments with two plungers 52). For instance, as shown in FIGS. 9 and 10, the left-side connecting element 80 is orientated rearward such that the left-side plunger 52 is in the extended position, while the right-side connecting element 80 is orientated forward such that the right-side plunger 52 is in the retracted position. Alternatively, although not shown in the drawings, the right-side connecting element 80 can be orientated rearward such that the right-side plunger 52 is in the extended position, while the left-side connecting element 80 can be orientated forward such that the left-side plunger 52 is in the retracted position. The plungers 52 being offset can allow for the spreading of drive loads and allows for smaller drive components.

In some embodiments, a point of connection between the left-side plunger 52 and the left-side connecting element 80 will be spaced from the axis of rotation of the first drive shaft section 76, such that the connection may be eccentrically shaped (i.e., the connecting element 80 may be an eccentric connection). In some embodiments, the first drive shaft section 76 may terminate at the left-side connecting element 80. In addition, in some embodiments, the point of connecting between the right-side plunger 52 and the right-side connecting element 80 will be spaced from the axis of rotation of the second drive shaft section 78, such that the connection may be eccentrically shaped (i.e., the connecting element 80 may be an eccentric connection). In some embodiments, the second drive shaft section 78 may terminate at the right-side connection element 80.

As was briefly noted above, in some embodiments, the left-side and right-side connecting elements 80 may be rotationally offset from one another with respect to the rotation of the first and second drive shaft sections 76, 78. In some specific embodiments, the left-side and right-side connecting elements 80 may be rotationally offset from one another by about one-hundred eighty degrees, about one-hundred twenty degrees, or about ninety degrees with respect to the axes of rotation of the first and second drive shaft sections 76, 78. In other embodiments, the left-side and right-side connecting elements 80 may be rotationally aligned with one another with respect to the axes of rotation of said first and second drive shaft sections 76, 78. In further embodiments, the relative rotational positioning of the left-side and right-side connecting elements 80 with respect to the rotation of said first and second drive shaft sections 76, 78 may either be i) aligned with one another or ii) offset from one another by an amount of rotational degrees approximately equal to three-hundred and sixty divided by the total number of reciprocating plungers 52 included in the baler 10. Thus, in embodiments of the baler 10 that include two plungers 52, the relative rotational positioning of the left-side and right-side connecting elements 80 with respect to the rotation of said first and second drive shaft sections 76, 78 may be about one-hundred and eighty degrees. Nevertheless, it should be understood that in some embodiments, the baler 10 may include more than two plungers 52, such that the connecting element 80 may be offset by different magnitudes.

In some further embodiments of the gearbox 70, the first drive shaft section 76 may include an auxiliary drive shaft 84, as perhaps best illustrated in FIGS. 3 and 9, which extends outwardly from and/or past the left-side connecting element 80. In alternative embodiments, the auxiliary drive shaft 84 may be included as part of the second drive shaft section 78 and may extend outwardly from and/or past the left-side connecting element 80. In further alternatives, the gearbox 70 may include a pair of auxiliary drive shafts 84, with one associated with each of the first drive shaft section 76 and the second drive shaft section 78. The baler 10 may comprise at least one auxiliary driven mechanism directly or indirectly powered by the auxiliary drive shaft 84. For example, such an auxiliary driven mechanism may comprise the pickup mechanism 22, the rotor 26, the stuffer assemblies 50, and/or one or more knotter assemblies (described in more detail below). The baler 10 may include one or more chains, belts, or the like that interconnect gears, sprockets, pulleys, etc. associated with the auxiliary drive shaft 84 and the auxiliary driven mechanisms. As such, the auxiliary drive shaft 84 can provide power (e.g., rotary power) to the auxiliary driven mechanisms.

For example, as illustrated in FIG. 1, a distal end of the auxiliary drive shaft 84 may include a sprocket, which rotates simultaneously with the auxiliary drive shaft 84. A chain may connect the sprocket of the auxiliary drive shaft 84 with a drive input assembly 86 associated with one of the stuffer assemblies 50 (e.g., the left-side stuffer assembly 50), as illustrated in FIG. 1. The drive input assembly 86 may include a sprocket that can be engaged with the chain extending from the sprocket of the auxiliary drive shaft 84. As such, the drive input assembly 86 may be configured to receive rotary power from the auxiliary drive shaft 84. As illustrated in FIG. 5, the drive input assembly 86 may be connected to the base element 50(a) of one of the stuffer assemblies 50 (e.g., the left-side stuffer assembly 50) via a connection element. As such, rotation of the drive input assembly 86 (as caused by the auxiliary drive shaft 84) will provide a corresponding rotation to the base element 50(a) of the left-side stuffer assembly 50, thereby powering the left-side stuffer assembly 50 for operation.

As described above, in certain embodiments, the baler 10 may include two stuffer assemblies 50. In some of such embodiments, one of the stuffer assemblies 50 (e.g., the left-side stuffer assembly 50) may be connected with the other stuffer assembly 50 (e.g., the right-side stuffer assembly 50), such that rotation of the left-side stuffer assembly 50 will cause a corresponding rotation of the right-side stuffer assembly 50. For example, as illustrated in FIG. 11, the left-side and right-side stuffer assemblies 50 may be interconnected by a connection element 87 that permits a rotation of one of the left-side or right-side stuffer assemblies 50 to cause a rotation of the other of the left-side or right-side stuffer assemblies 50. For instance, as discussed above, the auxiliary driveshaft 84 may provide rotational power to the left-side stuffer assembly via the drive input assembly 86. Such rotation of the left-side stuffer assembly 50 may cause a corresponding rotation of the right-side stuffer assembly via the connection element 87.

In some additional embodiments, as illustrated in FIG. 11, the base element 50(a) of the right-side stuffer assembly 50 may be connected to a drive output assembly 88 via a connection element. As will be described in more detail below, the drive output assembly 88 may be used to provide rotary power to other components of the baler 10.

Some embodiments provide for the left-side and right-side stuffer assemblies 50 to be offset by one-hundred and eighty degrees. As such, for instance, when the left-side stuffer assembly 50 is in an upward or top position, the right-side stuffer assembly 50 will be in the lower or bottom position. In addition, the position of the stuffer assemblies 50 may, in some embodiments, correspond with the positions of the plungers 52. For example, when the left-side stuffer assembly 50 is in the upward or top position, the left-side plunger 52 will be in the retracted position, such that crop material may be fed into the left-side baling chamber 18 by the left-side stuffer assembly 50. In such a configuration, the right-side stuffer assembly 50 will be in a lower or bottom position and the right-side plunger 52 will be in the extended position. As such, when the left-side stuffer assembly 50 is in the top position, the left-side plunger 52 will correspondingly be in the retracted position, such that crop material may be fed into the left-side baling chamber 18 from the left-side stuffer chute 28 by the left-side stuffer assembly 50 in preparation for compression stroke by the left-side plunger 52 to form a compacted square bale within the left-side baling chamber 18.

From the configuration discussed above, the gearbox 70 can rotate the stuffer assemblies 50, e.g., via the connection (e.g., the chains and sprockets) between the auxiliary drive shaft 84 and the stuffer assemblies 50 (e.g., via the drive input assembly 86), such that the right-side stuffer assembly 50 is shifted to the top position and the left-side stuffer assembly 50 is shifted to the bottom position. During such actuation, the gearbox 70 can simultaneously shift the right-side plunger 52 (e.g., via the second drive shaft element 78) to the retracted position and the left-side plunger 52 (e.g., via the first drive shaft element 76) to the extended position. As such, when the right-side stuffer assembly 50 is in the top position, the right-side plunger 52 will correspondingly be in the retracted position, such that crop material may be fed into the right-side baling chamber 18 by the right-side stuffer assembly 50 in preparation for compression stroke by the right-side plunger 52 to form a compacted square bale within the right-side baling chamber 18. In such a configuration, the left-side stuffer assembly 50 will be in the bottom position and the left-side plunger 52 will be in the extended position. As such, while the right-side plunger 52 is compacting crop material to form a bale, the left-side stuffer assembly 50 is in the downward position preparing to collect and push crop material upward through the left-side stuffer chute 28 once the left-side plunger 52 has been retracted.

In some embodiments, as shown in FIG. 1, the auxiliary drive shaft 84 may be further connected with the rotor 26 (e.g., via chain and sprockets), such that rotation of the auxiliary drive shaft 84 will cause actuation of the rotor 26 within the rotor housing 24. Similarly, in some embodiments, the auxiliary drive shaft 84 may be connected with the pickup mechanism 22 (e.g., via chain and sprockets), such that rotation of the auxiliary drive shaft 84 will cause actuation of the tined rotating member of the pickup mechanism 22. Alternatively, as shown in FIG. 2, the pickup mechanism 22 may be interconnected with the rotor 26 (e.g., via chain and sprockets), such that rotation of the rotor 26 (e.g., as perhaps caused by the auxiliary drive shaft 84) may cause a corresponding rotation of the tined rotating member of the pickup mechanism 22.

In addition to the auxiliary driven mechanisms discussed above, some embodiments of the baler 10 may include a plurality of knotter assemblies 90, as shown in FIGS. 1-3 and 11-13, for tying one or more securement lines (e.g., twine, wire, cord, etc.) around the square bales of crop material being formed in the baling chambers 18. In some embodiments, the baler 10 may include one knotter assembly 90 for each baling chamber 18, such that each bale of crop material may be wrapped and tied with securement lines. In some embodiments, each knotter assembly 90 may include a pair of knotting mechanisms 92, as illustrated in FIGS. 2, 3, and 11, each configured to wrap and tie a securement line around each square bale formed in the associated baling chamber 18. For instance, the left-side knotter assembly 90 may include a pair of knotting mechanisms 92, and the right-side knotter assembly 90 may include a pair of knotting mechanisms 92. As such, in some embodiments, the baler 10 may provide for each bale of crop material formed in each baling chamber 18 to be tied with two securement lines. Each knotting mechanism 92 may include the components necessary to apply a securement line around a bale of crop material and to securely tie/knot the securement line onto the bale. For example, each knotting mechanism 92 may include: a knotter disc, a billhook assembly (e.g., a billhook, a billhook spring, a billhook cam, a billhook pinion), strand holder, strand knife, etc. Each knotter assembly 90 may include a rotatable shaft 93, which may be configured as an axle, and which is configured actuate various of the components of the associated knotting mechanisms 92. As such, the left-side knotter assembly 90 may include one rotatable shaft 93, and the right-side knotter assembly may include one rotatable shaft 93.

In addition, each of the knotter assemblies 90 may include one or more needles 94, as illustrated in FIGS. 11-13, operably associated with each knotting mechanism 92. Each of the needles 94 may be used to wrap a securement line completely around a bale of crop material once the bale is fully formed, such that the associated knotting mechanism 92 can tie the securement line securely around the fully formed bale. FIG. 12 illustrates a needle in a lowered position, holding a securement line below a bale as the bale is being formed in the baling chamber 18. The securement line may be obtained from a spool of securement line held in an un-shown container or compartment of the baler 10. FIG. 13 illustrates the needle 94 in a raised position, such that the needle 94 brings the securement line up to the knotting mechanism 92 for tying off around the bale. Upon the needle 94 being lowered from the raised position, the needle 94 will start a subsequent strand of securement line around the subsequently-formed bale. It should be understood that FIGS. 12 and 13 illustrate a single knotting mechanism 92 and a single needle 94, which can be used to wrap and tie a single securement line around a bale. However, as was noted above, each knotter assembly 90 may include a plurality of knotting mechanisms 92 and a corresponding plurality of needles 94, such that each knotter assembly 90 can be configured to wrap and tie a plurality of (e.g., two) securement lines around a bales being formed in a baling chamber 18.

As illustrated in FIGS. 1 and 2, each knotter assembly 90 may additionally comprise a trip mechanism 96 that can be used to initiate the tying process once a bale of crop material has been fully formed. With reference to FIGS. 12 and 13, each trip mechanism 96 may include a starwheel 98, a measuring assembly 100, and a clutch mechanism 104 configured to permit associated knotting mechanisms 92 to tie a knot around a bale of crop material upon the bale being formed to a pre-selected size. In more detail, the starwheel 98 may be configured to engage a top surface of a bale of crop material as the bale is being formed within the baling chamber 18. Specifically, the starwheel 98 is configured walk along a top surface of the bale, such that the starwheel 98 rotates about a shaft 106 as the bale moves rearward through the baling chamber 18. The shaft 106 may be operably engaged with the measuring assembly 100, which comprises a notched arc and a pair of trip arms. As the starwheel 98 rotates, the shaft 106 will engage with the notched arc, so as to actuate the trip arms. The trip arms can be operably connected to the clutch mechanism 104. The clutch mechanism 104 may include a sprocket 105 that is constantly driven, directly or indirectly as will be discussed in more detail below, by the auxiliary drive shaft 84 of the gearbox 70. Embodiments provide for the clutch mechanism 104 to be selectively engaged so as to drive the rotatable shaft 93 and, thus, the knotting mechanisms 92 of the associated knotter assembly 90. In addition, the clutch mechanism 104 may also be operably connected to a needle frame 108 that supports the needles 94 of the associated knotter assembly 90, such that the selective engagement of the clutch mechanism 104 will actuate the needle frame 108 and the needles 94 thereon from the lowered position (e.g., FIG. 12) to the raised position (e.g., FIG.13). It should be understood that although FIGS. 12 and 13 illustrate the left-side knotter assembly 90 with the left-sided trip mechanism 96 discussed above, the right-side knotter assembly 90 includes a right-side trip mechanism 96 with generally the same components and that functions in generally the same manner as the left-sided trip mechanisms 96.

Embodiments provide for the trip mechanism 96 of each knotter assembly 90 to be particularly configured (e.g., due to a size of the starwheel 98 and/or to additional configurations of the measuring assembly 100) so as to initiate the tying of knots of the securement lines by each knotting mechanism 92 of the knotter assembly 90 once a bale has been fully formed to the appropriate size (e.g., the appropriate length). Broadly, the measuring assembly 100 will be configured to measure a size and/or length of bales being formed in the baling chambers 18. In more detail, as a bale of crop material is being formed in a baling chamber 18 (i.e., via the cyclical compressions of flakes of crop material by the reciprocating plunger 52), the bale will travel rearward through the baling chamber 18. In embodiments in which each knotter assembly 90 includes two knotting mechanisms 92, each knotting mechanism 92 will hold a securement line, such that the two securement lines will extend downward through the baling chamber 18 to tips of the respective needle 94. As the bale travels rearward, the two securement lines will wrap against a rear surface of the bale, as well as over a top and bottom of the bale, as illustrated in FIG. 12. During such travel, the starwheel 98 will walk along the top surface of the bale until the pre-determined bale length has been reached (e.g., as configured by the measuring assembly 100). At such time, the measuring assembly 100 will engage the clutch mechanism 104 so as to simultaneously cause rotation of the shaft 93 and actuation of the needle frame 108. Specifically, as shown in FIG. 13, the needle frame 108 will be actuated so as to force the pair of needles 94 upward, each bringing their securement line upward around a front side of the bale and adjacent to a corresponding knotting mechanism 92 that will tie the securement line securely onto the bale. The securement lines will be cut, so as to similarly allow for another securement line to be wrapped around and securely tied to a subsequently-formed bale of crop material. Upon being wrapped with the securement lines, the formed bale can be ejected from bale discharge at the rear end of the baling chamber 18.

In some alternative embodiments, the baler 10 may include trip mechanisms 96 that comprise electronic measuring assemblies that may include electrical and/or electro-mechanical components. For example, each starwheel 98 may be associated with an electronic sensor for measuring a length of the bale passing through the relevant baling chamber 18. The electronic sensor may be a rotary encoder, an optical sensor, or the like. The electronic sensor may measure the length of the bale passing through the associated baling chamber 18, and the resulting bale length data may be provided to an electronic control unit positioned on the baler 10 or on the tow vehicle The electronic control unit may include memory elements and processing elements configured to analyze the bale length data for a bale and to send resulting instructions to the clutch mechanism 104 upon the bale reaching a pre-determined bale length. In more detail, the electronic sensor may obtain bale length data for a given bale and may provide such bale length data to the electronic control unit. Upon the electronic control unit determining from the bale length data that the given bale has reached a fully-formed length (as may be pre-determined/pre-defined), the electronic control unit may send a signal or instruction to the clutch mechanism 104 to cause actuation of the knotting mechanisms 92 and related needles 94 so as to tie off securement lines around the fully formed bale. In embodiments in which the baler 10 includes multiple baling chambers 18 (each having its own starwheel 98 and clutch mechanism 104), each starwheel 98 may include its own electronic sensor for measuring the lengths of the bales being formed in its associated baling chamber 18. The electronic control unit may receive bale length data from each electronic sensor and may send independent instructions to each clutch mechanism 104 to tie off the bales in each baling chamber once each bale has been fully formed to the pre-determined bale length.

Beneficially, the knotter assemblies 90 of the baler 10 are configured to operate independently of one another. As such, the bales being formed in each of the baling chambers 18 can be wrapped and tied at different times, when the bales have been fully formed. For example, if two bales are being formed in the baler 10, one in the left-side baling chamber 18 and one in the right-side baling chamber 18, the left-side knotter assembly 90 can tie off the securement lines around the bale being formed in the left-side baling chamber 18 when the bale is fully formed (i.e., to the predetermined bale length), and the right-side knotter assembly 90 can tie off the securement lines around the bale being formed in the right-side baling chamber 18 when the bale is fully formed (i.e., to the predetermined bale length). However, because such bales may become fully formed at different times, e.g. due to variations in the amount of crop material being provided to the individual baling chambers 18, the knotter assemblies 90 associated with each baling chamber 18 may initiate tying of the securement lines at different times. As such, the baler 10 can be prevented from tying of short (or long) bales, which can create problems with stacking, transporting, and retailing of such bales. The independent operation of the knotter assemblies 90 will be described in further detail below.

In operation, the baler 10 described above may be configured to simultaneously produce multiple bales of crop material from a single windrow. The number of bales that may be simultaneously formed by the baler 10 is at least partly dependent on the number of baling chambers 18 included in the baler 10. As discussed above, the baler 10 may include a plurality of baling chambers 18. The embodiments shown in the drawings illustrate the baler 10 including two, inline baling chambers 18. However, it should be understood that certain embodiments of the baler 10 may include more than two baling chambers 18 (e.g., three, four, five, six, or more). In general, the baler 10 will be equipped with a number of stuffer chutes 28, stuffer assemblies 50, plungers 52, and knotter assemblies 90 that corresponds with and/or that is equal to the number of baling chambers 18. As such, the baler 10 will be configured to adequately provide crop material to each of the baling chambers 18 to create the bales of crop material.

The following example illustrates a baler 10 with a pair of baling chambers 18, which can be used to simultaneously form multiple square bales of crop material. As the baler 10 is pulled along its path of travel by the tow vehicle, the pickup mechanism 22 can pick up crop material from a single windrow of crop material. Particularly, the plurality of tines extending from the rotating member of the pickup mechanism 22 functions to pick up the crop material from the ground and to force the crop material upwardly and rearwardly to the rotor housing 24, with such flow of crop material illustrated by the arrows of FIGS. 4 and 5. From the rotor housing 24, the separation element 44 and the rotor 26 (e.g., due to the specific configurations of the auger flightings and/or toothed sections) are configured to separate the crop material into multiple streams for provisioning to the stuffer chutes 28. In the exemplary embodiment, the baler 10 may include two stuffer chutes 28, such that the separation element 44 and the rotor 26 are configured to separate the crop material into two generally equal streams of crop material and to provide one stream to each of the respective stuffer chutes 28 (e.g., the left-side and the right-side stuffer chutes 28).

While the crop material is in the stuffer chutes 28, the stuffer assemblies 50 of the stuffer chutes 28 will function to propel the crop material rearward and upward from the lower entrances of the stuffer chutes 28 to the upper exits of the stuffer chutes 28, as illustrated in FIG. 4. As the crop material is propelled rearward and upward, the crop material will also be pre-compressed due to the restricting size of the stuffer chutes 28. Upon the crop material reaching the upper exits of the stuffer chutes 28, the stuffer assemblies 50 will force charges of the crop material into the baling chambers 18. As was previously described, the two stuffer assemblies 50 may be offset by one-hundred and eighty degrees and may both be driven by the gearbox 70, such that the rotation of the stuffer assembles 50 are synchronized with the plungers 52 (which are also driven by the gearbox 70).

As such, in the embodiment of the baler 10 illustrated in the drawings (i.e., with two stuffer chutes 28, two stuffer assemblies 50, two baling chambers 18, and two plungers 52), the left-side stuffer assembly 50 can be rotated upward, due to actuation caused by the gearbox 70, so as to force a charge of crop material from into the crop inlet of the left-side baling chamber 18 (with the crop inlet being positioned on a bottom/forward side of the left-side baling chamber 18) while the left-side plunger 52 is in a retracted position. In such a configuration, the right-side stuffer assembly 50 will be in a lowered position and the right-side plunger 52 will be in an extended position. With a charge of crop material being added into the left-side baling chamber 18, the gearbox 70 can actuate the left-side plunger 52 to the extended position to compress the charge of crop material into flake of a bale of crop material. Such extension of the left-side plunger 52 will be accompanied, due to actuation caused by the gearbox 70, by a shifting of the right-side plunger 52 from the extended position to the retracted position. Simultaneously, the right-side stuffer assembly 50 can be rotated upward, due to actuation caused by the gearbox 70, so as to force a charge of crop material into the crop inlet of the right-side baling chamber 18 (with the crop inlet being positioned on a bottom/forward side of the right-side baling chamber 18) while the right-side plunger 52 is in a retracted position. With a charge of crop material being added into the right-side baling chamber 18, the gearbox 70 can actuate the right-side plunger 52 and can be extended to compress the charge of crop material into flake of a bale of crop material. Such actions can be repeated in a cyclical manner, as driven by the gearbox 70, so as to simultaneously form square bales of crop material in each of the left-side and right-side baling chambers 18.

As the bales are moving through each of the baling chambers 18 (e.g., the left-side and right-side baling chambers), the knotter assemblies 90 are configured to wrap and tie securement lines securely around the bales so as to hold the flakes of the bales together. Specifically, a left-side knotter assembly 90 may use its pair of knotting mechanisms 92 to wrap a pair of securement lines around the bales of crop material passing rearward through the left-side baling chamber 18. Upon the bale reaching the predetermined length, the trip mechanism 96 of the left-side knotter assembly 90 may cause the pair of needles 94 and the pair of knotting mechanisms 92 of the left-side knotter assembly 90 to actuate to complete the wrapping of the securement lines around the bale passing rearward through the left-side baling chamber 18 and to tie off the securement lines securely onto the bale. Similarly, a right-side knotter assembly 90 may use its pair of knotting mechanisms 92 to wrap a pair of securement lines around the bales of crop material passing rearward through the right-side baling chamber 18. Upon the bale reaching the predetermined length, the trip mechanism 96 of the right-side knotter assembly 90 may cause the pair of needles 94 and the pair of knotting mechanisms 92 of the right-side knotter assembly 90 to actuate to complete the wrapping of the securement lines around the bale passing rearward through the right-side baling chamber 18 and to tie off the securement lines securely onto the bale.

As was noted previously, the left-side and right-side knotter assemblies 90 may operate independently and at different times. To facilitate such independence, certain embodiments provide for the gearbox 70 to independently provide rotational power to each of the knotter assemblies 90. For example, in some embodiments, the auxiliary drive shaft 84 extending from the lift-side of the gearbox 70 may be connected (e.g., via chain and sprocket) to the sprocket 105 of the clutch mechanism 104 of the left-side knotter assembly 90. The sprocket 105 can, thus, be constantly driven by the auxiliary drive shaft 84 of the gearbox 70, such that the rotatable shaft 93 of the left-side knotter assembly can be actuated (in addition to the needles 94 of the left-side knotter assembly 90) when engaged by the clutch mechanism 104 upon command from the measuring assembly 100 of the left-side knotter assembly 90. Certain embodiments may provide for the right-side knotter assembly 90 to be driven in a similar manner by a second auxiliary drive shaft (not shown) extending from a right-side of the gearbox 70, such that the left-side and right-side knotter assemblies 90 may operate independently and at different times.

Alternatively, as illustrated in FIGS. 1, 2 and 11, each of the left-side and right-side knotter assemblies 90 may be independently driven by the auxiliary drive shaft 84 extending from the lift-side of the gearbox 70. Specifically, the auxiliary drive shaft 84 may be connected (e.g., via chain and sprockets) with the drive input assembly 86 so as to provide rotational power to the stuffer assemblies 50. In some embodiments, the drive input assembly 86 may include an additional sprocket for connecting (e.g., via a chain) with the sprocket 105 of the clutch mechanism 104 of the left-side knotter assembly 90, so as to provide rotational power to the left-side knotter assembly 90. In addition, the rotational power provided to the stuffer assemblies 50 via the drive input assembly 86 will cause a corresponding rotation of the drive output assembly 88 on the right-side of the baler 10. The drive output assembly 88 may be connected (e.g., via chain and sprocket) with the sprocket 105 of the clutch mechanism 104 of the right-side knotter assembly 90, so as to provide rotational power to the right-side knotter assembly 90. Thus, both the left-side and right-side knotter assemblies 90 may be driven by the auxiliary drive shaft 84 extending from the lift-side of the gearbox 70. Nevertheless, the left-side and right-side knotter assemblies 90 may operate independently and at different times based on the independent operation of their respective trip mechanisms 96.

Upon the bales of crop material being completely formed and tied off with securement lines, the bales may be ejected from ejection ports of the baling chambers 18. In some embodiments, the bales from each of the left-side and right-side baling chambers 18 will be ejected from the bale discharges of their respective baling chambers 18 in an alternating fashion. For example, due to the cyclical, reciprocating action of the left-side and right-side plungers 52, bales of crop material formed in the left-side baling chamber 18 may be completed in an alternating time periods with respect to bales formed in the right-side baling chamber 18. As such, the bales of crop material formed in the left-side and the right-side baling chambers 18 may be ejected in an alternating fashion. In different embodiments, the bales of crop material formed in the left-side baling chamber 18 may be ejected generally simultaneously as bales formed in the right-side baling chambers 18.

Although the invention has been described with reference to the one or more embodiments illustrated in the figures, it is understood that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. For example, the baler 10 illustrated and described above may be considered an “in-line” square baler, wherein the pickup mechanism 22, the stuffer chutes 28, the plungers 52, and the baling chambers 18 are orientated and/or aligned generally along fore-and-aft direction. As such, crop material is picked up from the windrow can flows in a generally in-line manner from the pickup mechanism 22 and the stuffer chutes 28 to the baling chambers 18. Regardless, the principles of the present invention may be equally applicable to various other square and rectangular baler designs. For example, it is contemplated that embodiments of the present invention may utilize a pickup mechanism 22 that is offset from (e.g., to one side of) the baling chambers 18.

The individual bales formed by the baler 10 may be ejected from the baling chambers 18 in series. For example, the left side baling chamber 18 may eject a first series of first individual bales (i.e., bales formed in a single row), while the right side baling chamber 18 may eject a second series of second individual bales (i.e., bales formed in a single row). Unfortunately, it can be cumbersome and time consuming to pick up and/or process bales formed in multiple series or rows. As such, embodiments of the present invention may further comprise a bale singulating system, such as singulator 200 illustrated in FIG. 14, for processing a first series of first individual bales and a second series of second individual bales into a single row of bales.

Before describing the singulator 200, it should be understood that the baler 10 can include multiple baling chambers 18 for simultaneous forming multiple individual rows of bales. For example, the embodiments shown in the drawings include two baling chambers 18, namely, a left side baling chamber 18 and a right side baling chamber 18. Each of the baling chambers 18 may present a bale-forming area in which the bales of crop material may be formed. However, it should also be understood that certain embodiments of the baler 10 may include a single baling chamber 18 that presents multiple bale-forming areas therein. For example, some embodiments of the baler 10 may include a single baling chamber 18 in which crop material is fed and separated by a knife to form two bales, with one bale being formed in one of two bale-forming areas defined within the single baling chamber 18 (i.e., one bale-forming area on either side of the knife). The baler 10 may, therefore, simultaneously form two individual bales (one bale in each bale-forming area), perhaps through use of two plungers 52 in a manner similar to that described above. In further embodiments, the single baling chamber 18 may have more than one knife, such that the single baling chamber 18 may include more than two bale-forming areas for simultaneously forming more than two bales. For example, the single baling chamber 18 may include two knives for simultaneously forming three bales within three bale-forming areas contained within the single baling chamber 18. In embodiments of the baler 10 that includes “n” number of knives within a single baling chamber 18, the baler 10 may simultaneously form “n+1” number of bales within “n+1” number of bale-forming areas presented by the single baling chamber 18.

As used herein, the term bale-forming area may refer to a single area bounded by the walls 54, 56, 58 of a single baling chamber 18, such that each baling chamber 18 of the baler 10 defines a single bale-forming area. Alternatively, the term bale-forming area may refer to one of a plurality of areas, the plurality of which are bounded by the walls 54, 56, 58 of a single baling chamber 18. Correspondingly, embodiments of the present invention provide for each baling chamber 18 of the baler 10 to include one or more bale-forming areas defined therein. In embodiments that include a plurality of bale-forming areas within a single baling chamber 18, each bale-forming area may be bound by one or more of the walls 54, 56, 58 of the baling chamber 18 and by a knife of the baling chamber 18. For example, in embodiments in which two bale-forming areas are included within a single baling chamber 18 comprising a single knife, a first/left side bale-forming area may be bound by a left sidewall 54, a top wall 56, a bottom wall 58, and the knife. Similarly, a second/right side bale-forming area may be bound by a right sidewall 54, a top wall 56, a bottom wall 58, and the knife. Once the crop material passes by the knife, the bales being formed in the first/left and second/right bale-forming areas may be adjacent to and contact each other as the bales continue to pass through the baling chamber 18.

As such, in certain embodiments in which a plurality of bale-forming areas are presented within a single baling chamber 18, the bale-forming areas may not be separated from each other. Instead, the bale-forming areas may be situated adjacent to each other with no space therebetween. However, as noted above, the bale-forming areas may be at least partly separated by the knife described above. In contrast, in embodiments in which each baling chamber 18 includes a single bale-forming area, the bale-forming areas may be separated from each other (e.g., by a space). In more detail, as described above with respect to the embodiments of the baler 10 that include two baling chambers 18, the left side baling chamber 18 may be separated by a space from the right side baling chamber 18. As such, the bale-forming areas within the left and right side baling chambers 18 may likewise be separated from each other.

Turning now to the singulator 200, as illustrated by FIG. 14, the singulator 200 may form part of the baler 10 and may extend rearward from the baling chambers 18 and/or from the bale-forming areas. For example, the singulator 200 may be connected to the baling chambers 18 and/or to the chassis 12 of the baler 10 in a manner that permits the singulator 200 to receive the first and second individual bales emitted from the baling chambers 18 (and/or emitted from the one or more bale-forming areas). Upon receiving the first and second individual bales, the singulator 200 may manipulate the first and second individual bales into a single row of bales that can be deposited onto the ground for efficient pickup by stacking machines or can be provided to a tow-behind bale accumulator for further sorting or grouping.

Turning to the singulator 200 in more detail, and with reference to FIGS. 14-18, the singulator 200 may comprises a landing section 202 and an exit section 204. The landing section 202 may be configured to receive the first and second individual bales from the baling chambers 18 (and/or from the bale-forming areas), and the exit section 204 may be configured to manipulate the bales into a single row. As such, at least a portion of the landing section 202 may be broad or wide enough to receive at least two side-by-side bales from the baling chambers 18 (and/or from the bale-forming areas). In contrast, at least a portion of the exit section 204 may be narrow enough (or otherwise configured) to not allow receipt of two side-by-side bales.

In some embodiments, the landing section 202 may be secured to the rearward ends of the baling chambers 18 and positioned directly below the outlets of the baling chamber 18. For example, as shown in FIGS. 14-16, the landing section 202 may be pivotally secured to a bottom side of the baling chambers 18 and supported in place via chain links that extends between the landing section 202 and an upper side of the baling chambers 18. In other embodiments, the landing section 202 may be secured to the chassis 12 of the baler 10. Nevertheless, in the configuration shown in FIGS. 14-16, the bales emitted from the baling chambers 18 (and/or from the bale-forming areas) can be received onto the landing section 202 in a side-by-side configuration. The landing section 202 may be secured to the baling chambers 18 in such a manner that the landing section 202 is oriented at angle, declining from front to back. As a result, the bales received on the landing section 202 can slide rearward on the landing section 202 under the force of gravity to the exit section 204. The orientation of the landing section 202 may be changed by extending or retracting the length of the chain links, such that the landing section 202 can increase or decrease the declination from the baling chambers 18 (via rotation around the landing section's 202 pivotal link to the baling chambers 18).

The exit section 204 may be secured to a rear side of the landing section 202, such that the singulating section is located behind the landing section 202. The exit section 204 may be orientated generally parallel with the landing section 202 such that the exit section 204 may be oriented at angle of decline as it extends from front to back. In some embodiments, the exit section 204 may be pivotally connected to a rear side of the landing section 202 such that the singulating section may be selectively orientated at a steeper angle than the landing section 202. Given the declination orientation of the exit section 204, the bales received on the exit section 204 from landing section 202 can slide rearward on the exit section 204 under the force of gravity

As will be discussed in more detail below, embodiments of the singulator described herein may include various transport mechanisms for moving the first and second individual bales from the landing section to the exit section and off the exit section. In addition to the use of gravity as described above (e.g., via gravity slide or a gravity dump), certain embodiments may include a transport mechanism selected from one or more of the following: a pushing element and a conveyor. For instance, the landing section 202 may be positioned generally horizontally and may include a conveyor mechanism for moving the bales from the landing section 202 to the exit section 204. An embodiment of a singulator that includes such a conveyor mechanism is described in more detail below.

Once the bales arrive at the exit section 204, the exit section 204 may be configured to manipulate the bales into a single, linear row of bales. For example, the singulator 200 may comprise, as illustrated in FIGS. 17 and 18, an exit section 204 with a pair of pusher members 210 positioned on left and right sides of the exit section 204. The pusher members 210 may be configured as elongated structural members that are configured to push bales towards a center of the singulator 200. In particular, a longitudinal centerline or longitudinal vertical plane may extend generally longitudinally (i.e., fore and aft) through the center of the singulator 200. As such, the center of the singulator 200 will generally include the longitudinal centerline or longitudinal vertical plane of the singulator 200.

In more detail, the pusher members 210 may comprise elongated tubular members formed from metal or another material with sufficient strength and durability. The exit section 204 may include one pusher member 210 secured on either lateral side of the exit section 204. As perhaps best shown in FIG. 17, a forward portion of a first pusher member 210 may be secured to a left side of the exit section 204, while a forward portion of a second pusher member 210 may be secured to a right side of the exit section 204. As connected to the exit section 204, the forward portions of the left and right pusher members 210 may be spaced apart sufficiently to present a receiving area that is sufficient to receive one or more side-by-side bales. The pusher members 210 may extend rearward and inward along a top surface of the exit section 204. As such, the distance between the left and right pusher members 210 may reduce as the pusher members 210 extend rearward, down the exit section 204. As a result, the pusher members 210 may cooperatively form a funnel shape. In more detail, the rearward potions of the pusher members 210 may be separated only by a distance sufficient to receive a single bale. Such an area (presented between the rearward portions of the pusher members 210) may be defined as an exit area that is narrow enough to not allow receipt of two individual bales positioned side-by-side.

In such a configuration, as illustrated by FIG. 18, bales can be released by each of the left and right baling chambers 18 (and/or by the first/left and second/right bale-forming areas) onto the landing section 202. As noted, the landing section 202 may be wide enough to support two, side-by-side bales. The bales can slide (e.g., side-by-side), under the force of gravity, rearward and down the landing section 202. However, once the bales reach the exit section 204, the pusher members 210 will function to singulate the bales into a single row of bales. Specifically, the bales will enter the generally wide receiving area presented between the forward portions of the pusher members 210. As the bales slide rearward, and down the exit section 204, the funnel shape of the pusher members 210 will function to push one of the bales laterally inward towards a center of the exit section 204 (e.g., which may include the longitudinal centerline or longitudinal vertical plane of the singulator 200) as the bales travel down to the exit area presented between the rearward portions of the pusher members 210. As such, one of the pusher members 210 (e.g., a left side pusher member) may be configured to push a first individual bale (e.g., a bale originating from the left side baling chamber 18) toward the center of the exit section 204, while the other pusher member 210 (e.g., a right side pusher member) is configured to push a second individual bale (e.g., a bale originating from the right side baling chamber 18) toward the center of the exit section 204. Such a pushing of the bales to the center of the exit section 204, as illustrated in FIG. 18, will cause the bales to line up in a single, row, where the bales can be dropped off the singulator 200 onto the ground (forming a single row of bales) or can be picked up from the singulator 200. In addition to the generally stationary pusher members 210, certain embodiments may provide for the pusher members 210 to be actuatable, e.g., via hydraulic cylinders. In such embodiments, the pusher members 210 may be selectively/periodically actuated inward, so as to aid in pushing the bales laterally inward toward the center of the exit section 204

As perhaps best shown in FIG. 17, the pusher members 210 may, in some embodiments be pivotally secured to the exit section 204. Specifically, forward portions of the pusher members 210 may be pivotally secured to the exit section 204 via brackets 212. Such a pivotal connection allows the pusher members 204 to at least partially flex outwards when a force is applied to inner portions of the pusher members 204. Such flexing may be beneficial to prevent jamming of the singulator 200 when processing bales of various sizes or when the singulator 200 encounters obstacles or debris. For example, FIG. 18 illustrates the pusher members 210 flexing outward as a bale passes through the exit area presented between the pusher members 210. After the bale has completely passed through, the pusher members 210 can return to their original positions via the force of a bias assembly 214, as illustrated in FIG. 15. The bias assembly 214 may comprise a spring connecting the forward portions of each of the pusher members 210 (e.g., via the brackets 212) to the underside of the exit section 204. As such, the bias assembly 214 can function to bias the pusher members 210 in a laterally inward position, so as to return to such position after having been flexed outwards. In alternative embodiments, the bias assembly 214 may include a single spring that connects the forward portions of the pusher members 210 so as to bias the pusher members in the laterally inward position.

Finally, it should be noted that in some embodiments, the singulator 200 may be folded forward adjacent to the remaining components of the baler 10 (e.g., adjacent to the baling chamber 18 and/or the chassis 12) for convenience during transport of the baler 10. For example, the connection between the landing section 202 and the baling chambers 18 may allow for the landing section 202 to be pivoted upward/downward and adjacent to the baling chambers 18 and/or to the chassis 12. Similarly, the exit section 204 may be pivoted upward/downward and adjacent to the landing section 202. Such shifting/folding of the landing section 202 and the exit section 204 reduces the footprint of the baler 10, which can aid in transport and storage of the baler 10.

An additional embodiment of a singulator 220 is illustrated in FIG. 19-22. As with the singulator 200, the singulator 220 may be secured to a rear side of other components of the baler 10, such as to the rear of the baling chambers 18 and/or to the chassis 12. In some embodiments, as shown in FIG. 19, the singulator 220 may include a chassis extension 221, which comprises a rigid support assembly on which the other components of the singulator 220 can be supported.

The other components of the singulator 220 may include a landing section 222 and an exit section 224. The landing section 222, on which first and second individual bales may be deposited by the left and right baling chambers 18 (and/or by the first/left and second/right bale-forming areas), respectively, may comprise a first dump cradle 226 (e.g., a left side dump cradle) and a second dump cradle 228 (e.g., a right side dump cradle), each movable between a bale-receiving position and a bale-dumping position. FIGS. 19-22 illustrate each of the dump cradles 226, 228 in the bale-receiving position. FIG. 23 shows the left side dump cradle 226 rotated downward in the bale-dumping position, and FIG. 24 shows the right side dump cradle 228 rotated downward in the bale-dumping position. In the bale-receiving position, the left side dump cradle 226 can receive and support an individual bale ejected from the left side baling chamber 18 (and/or by the first/left bale-forming area). Similarly, in the bale-receiving position, the right side dump cradle 228 can receive and support an individual bale ejected from the right side baling chamber 18 (and/or by the second/right bale-forming areas). In contrast, in the bale-dumping position, the left side dump cradle 226 is configured to dump an individual bale that was received from the left side baling chamber 18 down onto the exit section 224. Likewise, in the bale-dumping position, the right side dump cradle 228 is configured to dump an individual bale that was received from the right side baling chamber 18 down onto the exit section 224.

The dump cradles 226, 228 may be supported in positions adjacent to the rear of the baling chambers 18 via upright supports that extend upward from the chassis extension 221. As such, the landing section 222 (which includes the dump cradles 226, 228) may be positioned above the exit section 224, as will be discussed in more detail below.

Each of the dump cradles 226, 228 may comprise an elongated base panel that is rotatably connected to one or more of the of the upright supports. The base panels may have a length that is generally the same length as (or longer than) a bale being formed by the baler. The dump cradles 226, 228 may be actuated between the bale-receiving and the bale-dumping positions (and vice versa) via dump actuators that extend from the upright supports to the dump cradles 226, 228. In some embodiments, the dump actuators may comprise hydraulic cylinders. As such, the singulator 220 may be associated with a hydraulic system (e.g., a pump, a reservoir, lines, etc.) for selectively providing hydraulic power to the cylinders. In some embodiments, the upright supports may each also include an elongated side support panel that works in cooperation with a respective dump cradle 226, 228 to support a bale. Specifically, when the dump cradles 226, 228 are in the bale-receiving position, the base panels are generally horizontal so as to be able to support a bale (in conjunction with the side support panels). In contrast, when the dump cradles 226, 228 are in the bale-dumping position, the base panels are shifted (i.e., rotated downward) to a non-horizontal or a downwardly oriented position, such that the dump cradles 226, 228 will not support a bale and the bale will drop down onto the exit section 224.

In more detail, when in the bale-receiving position, each of the dump cradles 226, 228 may be configured to support an individual bale ejected from one of the baling chambers 18. To facilitate the reception of the bales, the dump cradles 226, 228 may be positioned directly rearward and/or below the baling chambers 18, with the left side dump cradle 226 rearward and/or below of the left side baling chamber 18 and the right side dump cradle 228 positioned rearward and/or below of the right side baling chamber 18. As such, when the left side dump cradle 226 is in the bale-receiving position (See, e.g., FIGS. 22 and 24), the left side baling chamber 18 can emit a bale that is received onto the left side dump cradle 226. Similarly, when the right side dump cradle 228 is in the bale-receiving position (See, e.g., FIGS. 22 and 23), the left side baling chamber 18 can emit a bale that is received onto the left side dump cradle 228.

Each of the dump cradles 226, 228 may include a sensor 229 for determining when a bale has been completely received on a given dump cradle 226, 228 from the respective baling chamber 18. The sensors 229 may comprise electro-mechanical switches positioned on rearward ends of the dump cradles 226, 228, as shown in FIG. 22. In some embodiments, the sensors 229 may comprise non-contact inductive proximity sensors configured to detect a position of a cover panel that is selectively positioned over a base element. The cover panel may be biased, via a spring, in an open position in which the cover panel is rotated away from the base element. However, the cover panel may be pushed rearward to a closed position in which the cover panel is positioned directly over the base element. The cover panel being in the closed position is indicative of a bale being completely positioned on the respective dump cradle 226, 228, as describe below.

In operation of the baler 10, a bale being ejected from a bailing chamber 18 will slide rearward on a dump cradle 226, 228. Once the bale has been completely ejected onto a dump cradle 226, 228, the bale will make contact with the sensor 229 (i.e., shifting the cover panel rearward over the base element), which will provide an indication that the bale has been completely received on the dump cradle 226, 228. In some embodiments, the sensors 229 may be in communication with the dump actuators that will cause the dump cradle 226, 228 to transition from the bale-receiving position to the bale-dumping position when a bale has been completely received on the dump cradle 226, 228. Alternatively, the sensors 229 may be in communication with a control system (not shown) that instructs the dump cradles 226, 228 to transition from the bale-receiving position to the bale-dumping position when a bale has been completely received on the dump cradle 226, 228.

Turning now to the exit section 224 in more detail, as perhaps best shown in FIG. 25, the exit section 224 may comprise a concave shaped receiving tray 230 which is supported on the chassis extension 221. As such, the exit section 224 (which includes the receiving tray 230) may be positioned below the landing section 222 (which includes the dump cradles 226, 228). In more detail, the receiving tray 230 may comprise a generally trough-shaped central platform comprising inwardly/downwardly sloping sides that extend down to a central base. The exit section 224 may additionally include a conveyor 232, as perhaps best show in FIG. 21. The conveyor may comprise one or more paddles 234 that are propelled along an upper surface of the receiving tray 230 by a drive system. The drive system may be a belt drive, chain drive, gear drive, or other similar drive mechanism. The drive system may be driven by rotary power obtained from the PTO of the tractor, or by other power sources (e.g., hydraulic or electric power sources) The conveyor 232 may extend longitudinally along the central base of the receiving tray 230. As perhaps best illustrated in FIG. 25, the central base of the receiving tray 230 may be formed with a gap that extends along a longitudinally along a center of the receiving tray 230. As such, the drive system of the conveyor 232 may be positioned underneath the receiving tray 230 and the paddles 234 can extend upward through the gap. As such, the paddles 234 can be actuated along the upper surface of the receiving tray 230 to push bales rearward on the upper surface of the receiving tray 230, as will be discussed in more detail below.

In some embodiments, as perhaps best illustrated by FIGS. 25-27, movement of the conveyor 232 can be initiated by one or more enlarged button switches 236 that extend up through cutouts formed in the receiving tray 230. As shown in FIGS. 25 and 26, the singulator 220 may include two switches 236, with one switch 236 positioned on either side of the gap formed through the receiving tray 230. The switches 236 may be in communication with the conveyor 232, such that actuation (e.g., depression) of one or both of the switches 236 instructs the conveyor 232 to actuate, such that the paddle 234 is caused to move rearward along the upper surface of the receiving tray 230 to push a bale rearward. Alternatively, the switches 236 may be in communication with the previously described control system, which can instruct the conveyor 232 to actuate, such that the paddle 234 is caused to move rearward along the upper surface of the receiving tray 230 to push a bale rearward.

Finally, the exit section 224 may include a funnel outlet 238, as illustrated in FIGS. 19-21, positioned rearward of the receiving tray 230. The funnel outlet 238 may be supported on the chassis extension 221. The funnel outlet 238 may comprise a base panel surrounded by funnel-shaped sidewalls. The separation distance between the sidewalls may reduce from front to rear, so as to give the sidewalls their funnel shape. As a result of the shape, bales passed to the funnel outlet 238 (e.g., via the from the receiving tray 230 as will be discussed below) will be generally centered in alignment with a longitudinal centerline or a longitudinal vertical plane extending through the singulator 220. As such, bales can be deposited from he funnel outlet 238 (e.g., onto the ground) in a single row.

In operation, the singulator 220 can receiving first and second individual bales from the baling chambers 18 (and/or from the baling areas) and manipulate the individual bales such that the individual bales are configured in a single row of bales. In more detail, as shown in FIG. 28, the right side dump cradle 228 is configured to receive first individual bales from the right side baling chamber 18 (and/or from the second/right bale-forming area) when the right side dump cradle 228 is in the bale-receiving position. Specifically, as a first individual bale is ejected from the right side baling chamber 18 (and/or from the second/right bale-forming area), the bale will slide along the right side dump cradle 228 until the bale is completely supported on the right side dump cradle 228. At such time, the bale will make contact with the sensor 229 associated with the right side dump cradle 228, which will cause the right side dump cradle 228 to shift (e.g., rotate downward) to the bale-dumping position, as shown in FIG. 29. Such shifting will cause the first individual bale to drop down onto the receiving tray 230. The downwardly sloping sides of the receiving tray 230 will direct the bale laterally inward towards the center of the receiving tray 230, such that the bale will make contact with one or more of the switches 236, thereby depressing the one or more switches. Actuation of the switches will correspondingly cause activation of the conveyor 232.

FIG. 30 illustrates the first individual bale supported in the center (or center portion) of the receiving tray 230. As show, one of the paddles 234 of the conveyor 232 is positioned directly forward of the bale (e.g., on the front side of the receiving tray 230). Upon the bale depressing one or more of the switches 236, the conveyor 232 will be activated, causing the paddle 234 to shift rearward, thus forcing the first individual bale rearward along the receiving tray as shown in FIG. 31. The conveyor 232 will be activated for a sufficient time period to allow the paddle 234 to force the bale off the receiving tray and onto the funnel outlet 238. In particular, the conveyor 232 may be activated for a time period sufficient to permit the paddle 234 to be actuated from the front side of the receiving tray 230 to a rear side of the receiving tray 230. Such actuation may be one-half of a rotation cycle of the conveyor 232. In some embodiments, the conveyor 232 may include two paddles 234 on opposite sides of the conveyor 232, such that when one paddle 234 is on the front side of the receiving tray 230 the other paddle 234 is on the rear side of the receiving tray 230. As a result, once a first paddle 234 has been shifted to the rear end of the receiving tray 230 and has pushed the first individual bale off the receiving tray 230, the conveyor 232 can be deactivated with a second paddle 234 being positioned at the front side of the receiving tray 230 ready to receive push a second individual bale reward.

In some embodiments, the first individual bale will be forced out of the funnel outlet 238 and onto the ground via actuation of the conveyor 232. However, in some other embodiments, the first individual bale may remain on or in the funnel outlet 238 until a subsequent bale forces the first individual bale off the funnel outlet under power form the conveyor 232.

The above process for moving the first individual bale rearward through the singulator 220, as shown in FIG. 32, can be repeated with the second individual bale that is ejected from the left side baling chamber 18 (and/or from the first/left bale-forming area) onto the left side dump cradle 226. Specifically, the left side dump cradle 226 is configured to receive the second individual bales from the left side baling chamber 18 (and/or from the first/left bale-forming area) when the left side dump cradle 226 is in the bale-receiving position. Upon the second individual bale being completely supported on the left side dump cradle 226, the bale will trip the sensor 229, and the left side dump cradle 226 will dump the bale down onto the receiving tray 230. The second individual bale will be directed laterally inward by the concave shape of the receiving tray 230, such that the bale will depress one or more of the switches 226 so as to cause the conveyor 232 to shift the second individual bale rearward off the receiving tray 230 and onto the funnel outlet. In some embodiments, the conveyor 232 will force the second individual bale into contact with the first individual bale that is positioned on the funnel outlet 238, such that the first individual bale will be forced off the baler 10 onto the ground. Regardless, the singulator 220 described above is configured to manipulate first and second individual bales received from separate baling chambers 18 (and/or from individual bale-forming areas) into a single row of bales.

In some embodiments, the singulator 220 may be associated with a control system for controlling certain functionality of the singulator 220. The control system may comprise one or more processing elements and/or memory elements. The memory elements may store a computer program or application, which when executed by the processing elements, functions to control such certain operations of the singulator 220. In particular, the control system may be functionally coupled with the sensors 229, the switches 236, the dump cradles 226, 228, and/or the conveyor 232 such that the control system may receive information from such components and provide resulting instructions to such components. As was noted previously, the baling chambers 18 (and/or the bale-forming areas) may be configured to form individual bales simultaneously. However, the individual bales may be completed within and eject from the baling chambers 18 (and/or the bale-forming areas) at different times. For instance, the left side baling chamber 18 (and/or the first/left bale-forming area) may finish forming a first individual bale and may eject the individual bale onto the left side dump cradle 226. Thereafter (e.g., 10 seconds later), the right side baling chamber 18 (and/or the second/right bale-forming area) may finish forming a second individual bale and may eject the bale onto the right side dump cradle 228. Nevertheless, some operational conditions may allow for the left and right baling chambers 18 (and/or the first/left and second/right bale-forming areas) to finish forming individual bales at nearly the same time, such that the left and right baling chambers 18 (and/or the first/left and second/right bale-forming areas) will eject the individual bales onto the dump cradles 226, 228 at nearly the same time.

It may be problematic if multiple bales are dropped by the dump cradles 226, 228 at the same time onto the receiving tray 230, as jamming of the singulator 220 may occur. To address such concerns, the control system may be configured control operation of the singulator 220 to ensure that only one individual bale is dumped onto the receiving tray 230 at a time. For instance, with the first individual bale being supported on the left side dump cradle 226 in the bale-receiving position, the first individual bale may trip the sensor 229 associated with the left side dump cradle 226. The sensor may provide an indication (e.g., a signal) to the control system that the first individual bale is completely received on the left side dump cradle 226, and the control system may instruct the left side dump cradle 226 to shift to the bale-dumping position so as to dump the first individual bale onto the receiving tray 230. As the first individual bale is dumped onto the receiving tray 230, the bale will be forced laterally inward toward a center of the receiving tray 230 due to the inwardly/downwardly sloping sidewalls of the receiving tray 230. The first individual bale will, thus, make contact with one (or both) of the switches 236, which will send an indication (e.g., a signal) to the control system of the centered positioning of the bale on the receiving tray 230. As such, the control system will instruct the conveyor 232 to activate such that the paddle 2340 will push the first individual bale rearward across and off the receiving tray 230 and onto the funnel outlet 238.

During such activity with respect to the first individual bale, the right dump cradle 228 may be in the bale-receiving position and may be supporting a second individual bale that was ejected from the right side baling chamber 18 (and/or the second/right bale-forming area). The second individual bale may be completely positioned on the second dump cradle 228, such that the bale has tripped the sensor 229 associated with the right dump cradle 228. As such, the sensor 229 may provide an indication (e.g., a signal) to the control system that the second individual bale is completely received on the right dump cradle 228. However, the control system may be configured to not instruct the right dump cradle 228 to shift to the bale-dumping position until the first individual bale has been completely moved off the receiving tray 230. In particular, the control system may be configured to not instruct the right dump cradle 228 to shift to the bale-dumping position until the conveyor 232 has been activated for one-half of a rotation, at which time the first individual bale has been pushed rearward off the receiving tray 230 by a first paddle 234 of the conveyor 232. As such, the receiving tray 230 will be generally empty and a second paddle 234 will be positioned at a forward end of the receiving tray 230, such that the receiving tray 230 is open to receive the second individual bale from the right side dump cradle 228, such that the second individual bale can be pushed rearward by the second paddle 234 of the conveyor 232. In such a manner, the control system may control operation of the singulator 220 in a manner that manipulates first and second individual bales into a single line of bales without the singulator 220 becoming jammed.

In some further embodiments, the singulator 220 may be incorporated with a scale or other sensor for measuring a weight of individual bales. In some embodiments, the scales may be incorporated within the landing section 222. For instance, each of the dump cradles 226, 228 may include or be associated with a scale to measure a weight of each bale supported on the dump cradle 226, 228. Alternatively, the scales may be incorporated within the exit section 224. For instance, the receiving tray 230 be associated with a scale to measure a weight of each bale supported thereon. The scales may be communicatively coupled with the control system to use resulting weight data in furtherance of control of the singulator 220. The weight data may also be stored for further analysis by the operator of the baler 10.

A further embodiment of a singulator 240 is illustrated in FIG. 33. As with the singulators 200, 220, the singulator 240 may be secured to a rear side of other components of the baler 10, such as to the rear of the baling chambers 18 and/or the chassis 12. The singulator 240 may include a landing section 242 and an exit section 244. The landing section 242, on which first and second individual bales may be deposited by the left and right baling chambers 18 (and/or the first/left and second/right bale-forming areas), respectively, may comprise a first lift cradle 246 (e.g., a left side lift cradle) and a second lift cradle 248 (e.g., a right side lift cradle), each movable between a bale-receiving position and a bale-ejecting position. FIG. 33 illustrates each of the lift cradles 246, 248 in the bale-receiving position. FIG. 34 shows the left side lift cradle 246 in the bale-ejecting position, and FIG. 35 shows the right side lift cradle 248 in the bale-ejecting position. In the bale-ejecting position, the left side lift cradle 246 can receive an individual bale from the left side baling chamber 18 (and/or the first/left bale-forming area). Similarly, in the bale-receiving position, the right side lift cradle 248 can receive an individual bale from the right side baling chamber 18 (and/or the second/right bale-forming area). In contrast, in the bale-ejecting position, the left side lift cradle 246 is configured to lift and eject an individual bale that was received from the left side baling chamber 18 (and/or the first/left bale-forming area). Likewise, in the bale-ejecting position, the right side lift cradle 248 is configured to lift and eject an individual bale that was received from the right side baling chamber 18 (and/or the second/right bale-forming areas). As such, the lift cradles 246, 248 are configured to lift the first and second individual bales, respectively, when moved between the bale-receiving position and said bale-ejecting position.

Each of the lift cradles 246, 248 may comprise one or more base supports and one or more side supports. In some embodiments, the base supports and side supports may be formed from a single piece of material formed in an “L” shape. The lift cradles 246, 248 may each be associated with an actuator (e.g., a hydraulic cylinder) that functions to rotate and raise its respective lift cradle 246, 248 laterally inward and upward from the bale-receiving position to the bale-ejecting position. The lift cradles 246, 248 may be rotatably connected to the baling chambers 18, the chassis 12, and/or the exit section 244 in a manner that allows the lift cradles 246, 248 to be rotated/raised to the bale-ejecting positions in which the lift cradles 246, 248 are positioned at least partially above the exit section 244.

When the lift cradles 246, 248 are in the bale-receiving position, the base supports are generally horizontal so as to be able to support a bottom portion of the bales, while the side supports are oriented vertically to support a side surface of the bales. In the bale-receiving position, the lift cradles 246, 248 will be positioned below at least part of the exit section 244. In contrast, when the dump cradles 226, 228 are rotated/raised to the bale-dumping position, the base supports and the side supports are shifted (i.e., rotated upward) to non-horizontal and non-vertical positions, respectively, such that the lift cradles 246, 248 will not support the bales and the bales can be deposited onto the exit section 244.

The exit section 244 present a central platform comprising a main central platform 250 that is configured to receive individual bales. The main central platform 250 may be sufficiently wide to only receive a single individual bale. The exit section 244 may further include an outlet slide 252 that is connected to a rearward end of the main central platform 250. The individual bales may be moved from the main central platform 250 to the outlet slide 252 via a conveyor or other type of pushing element. Once on the outlet slide 252, the bales can slide rearward under the force of gravity and off the singulator 240 onto the ground. Alternatively, the main central platform 250 may be configured to be rotated downward (e.g., under power of a hydraulic cylinder) so as to be selectively orientated at a declination angle that matches that of the outlet slide 252. As such, when the main central platform 250 is rotated downward, a bale can slide rearward off the main central platform 250 under the force of gravity and on to the outlet slide 252, where the bale can continue sliding down and off the singulator 240. As such, the singulator 240 is configured to receive first and second individual bales from the left and right side baling chambers 18 (and/or the first/left and second/right bale-forming areas), respectively, and to singulate such bales in a manner that allows the bales to be aligned in a single row.

Having thus described one or more embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following: 

What is claimed is:
 1. A square baler comprising: a first bale-forming area in which are formed a first series of first individual bales; a second bale-forming area in which are formed a second series of second individual bales; and a singulator configured to receive the first and second individual bales from said first and second bale-forming areas and to form a single row of said first and second individual bales.
 2. The square baler of claim 1, wherein said first bale-forming area is presented within a first baling chamber and said second bale-forming area is presented within a second baling chamber.
 3. The square baler of claim 2, wherein said first and second bale forming chambers are configured to release first individual bales and the second individual bales at different times.
 4. The square baler of claim 1, wherein said first and second bale-forming areas are spaced apart from one another.
 5. The square baler of claim 1, wherein said singulator is positioned rearward of said first and second bale-forming areas.
 6. The square baler of claim 5, wherein said singulator comprises a broad landing section and a narrow exit section, wherein said landing section is wide enough to receive at least two individual bales positioned side by side from said bale-forming areas, wherein said exit section is narrow enough to not allow receipt of two individual bales positioned side by side.
 7. The square baler of claim 6, wherein said exit section is located rearward of said landing section.
 8. The square baler of claim 6, wherein at least a portion of said exit section is located below said landing section.
 9. The square baler of claim 6, wherein said singulator comprises at least one transport mechanism for moving said first and second individual bales from said landing section to said exit section
 10. The square baler of claim 9, wherein said transport mechanism comprises a conveyor.
 11. The square baler of claim 1, wherein said singulator is configured to transport the first and second individual bales from said landing section to said exit section under a gravitational force.
 12. The square baler of claim 1, wherein said singulator comprises at least one pusher member configured to laterally push the first or second individual bales.
 13. The square baler of claim 1, wherein said singulator comprises a first pusher member and a second pusher member configured to laterally push the first individual bale and the second individual bale, respectively.
 14. The square baler of claim 13, wherein said singulator comprises a central section that includes a longitudinal centerline of said singulator, wherein said first pusher member is configured to push said first individual bales toward said central section, wherein said second pusher member is configured to push said second individual bale toward said central section.
 15. The square baler of claim 1, wherein said singulator comprises first and second dump cradles, with each movable between a bale-receiving position and a bale-dumping position.
 16. The square baler of claim 15, wherein said first dump cradle is configured to receive said first individual bales from said first bale-forming area when said first dump cradle is in said bale-receiving position, wherein said second dump cradle is configured to receive said second individual bales from said second bale-forming area when said second dump cradle is in said bale-receiving position, wherein said first dump cradle is configured to dump said first individual bale off said first dump cradle when said first dump cradle is in said bale-dumping position, wherein said second dump cradle is configured to dump said second individual bale off said second dump cradle when said second dump cradle is in said bale-dumping position.
 17. The square baler of claim 16, wherein said singulator further comprises a central platform for receiving said first and second bales dumped by said first and second dump cradles, wherein said central platform is positioned below said first and second dump cradles.
 18. The square baler of claim 17, wherein said singulator further comprises a platform conveyor for moving said first and second bales rearward and off said central platform.
 19. The square baler of claim 1, wherein said singulator comprises first and second lift cradles, each movable between a bale-receiving position and a bale-ejecting position, wherein said first and second lift cradles are configured to lift said first and second bales, respectively, when moved between said bale-receiving position and said bale-ejecting position.
 20. The square baler of claim 19, wherein said singulator further comprises a central platform for receiving said first and second bales ejected by said first and second lift cradles, wherein said central platform is positioned above said first and second lift cradles.
 21. The square baler of claim 1, wherein said singulator comprises a scale for measuring a weight of said first and second bales.
 22. A method of sorting a plurality of bales of crop material, said method comprising the steps of: (a) forming bales of crop material within a first bale-forming area and a second bale-forming area; (b) dispensing a first series of first individual bales from the first bale-forming area; (c) dispensing a second series of second individual bales from the second bale-forming area; and (d) positioning the first and second individual bales dispensed respectively from the first and second bale-forming areas into a single row of bales.
 23. The method of claim 22, wherein said positioning of step (d) is performed by a singulator that is positioned rearward of said first and second bale-forming areas.
 24. The method of claim 23, wherein the singulator comprises a broad landing section and a narrow exit section, wherein the landing section is wide enough to receive at least two individual bales positioned side-by-side from the bale-forming areas, and wherein the exit section is narrow enough to not allow receipt of two individual bales positioned side-by-side.
 25. The method of claim 23, wherein the first and second bales travel through the singulator under the force of gravity.
 26. The method of claim 23, wherein the first and second bales travel through the singulator via a conveyor.
 27. The method of claim 22, wherein the first and second bale-forming areas are spaced apart from one another. 